Knee pad

ABSTRACT

Disclosed are knee pad assemblies, methods and systems comprising a knee pad base and an outer cover that forms the contacting surface of the knee pad. A removable cover may be secured to a knee pad base. Replacement cover configurations may be provided that are adapted to various surfaces, including roofing, tile, wood, carpet, concrete and asphalt. The knee pad base can be adapted for different user weights and durations for wearing the pad. The outer cover can provide a floating suspension. The knee pad base may be held in place on knee of the user by various mechanisms. The restraint mechanisms can be adjusted by the user. The knee pad assembly can also include a tension/release mechanism so that strap tension is decreased or released when kneeling but increases tension or engage when the user stands to retain the knee pad in the desired location.

CLAIM OF BENEFIT TO PRIOR APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/475,656 filed Apr. 14, 2011, and such application is hereby fully and entirely incorporated by reference herein.

FIELD

The present invention generally relates to knee pads, systems for protecting the knee and methods for knee protection.

BACKGROUND

Protective knee pads are used by various types of individuals, including construction workers, mechanics, sportsmen, athletes, and others who find it necessary to protect their knees as a result of their work or activities. This is particularly the case when kneeling on a hard surface. Utilization of protective knee pads placed on or around the knee for use when kneeling on hard surfaces is common practice and, in some instances, a requirement in order to effectively engage in a trade or craft. Various knee pad configurations are available and many typically comprise a rigid case or outer shell which is padded on the inside surface, is shaped to be fitted over the knee and includes attachment straps for retention on or over the knee.

One drawback associated with the use of knee pads relates to the adaptability of the knee pad to a variety of surfaces. A knee pad with an outer gripping or cushioning surface may be well suited for one particular type of application or use, but poorly suited for use in another location or on another surface. As a result, a worker may need to purchase many different types of knee pads or use a knee pad that is not well suited to the particular use, which may be unsafe.

Another drawback associated with the use of knee pads relates to the outer surface of the knee pad wearing out, thus necessitating costly replacement of the entire pair of knee pads. Replacing a set of knee pads every time one of the pads wears out is both costly and is not environmentally friendly.

A further drawback is that the retention straps used to hold the knee pads in place may be uncomfortable for the user to wear for extended periods of time and may promote fatigue.

An additional drawback to current knee pads is that heavier users may not be provided with sufficient comfort and protection.

Therefore, there is a need for an improved knee pad assembly, knee pad system and method of protecting the knees of a user.

SUMMARY

The present disclosure is directed to knee pad assemblies, methods and systems comprising a knee pad base and an outer cover that forms the contacting surface of the knee pad. In certain embodiments, a removable cover is securable to a knee pad base. A variety of cover configurations may be provided that are adapted to various surfaces, including roofing, tile, wood, carpet, concrete and asphalt. The knee pad base can be adapted for different user weights and durations for wearing the pad. The outer cover can be secured to the base using a variety of mechanisms disclosed herein or variations thereof. The knee pad base is held in place on knee of the user by various mechanisms disclosed herein and variations thereof. The restraint mechanisms can be adjusted by the user. The knee pad assembly can also include a tension/release mechanism so that strap tension is decreased or released when kneeling but would increase or engage tension when the user stands to retain the knee pad in the desired location.

Additional features and advantages of the invention will be apparent from review of the written disclosure herein and consideration of the appended drawings.

The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations, whether or not explicitly disclosed, or in isolation, without departing from the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an analytic perspective view of a knee pad assembly and knee pad cover according to example embodiments.

FIG. 2 is a perspective view of the knee pad assembly of FIG. 1.

FIG. 3 is an analytic perspective view of a knee pad assembly and knee pad cover according to example embodiments.

FIG. 4 is a perspective view of the knee pad assembly of base 202 from FIG. 3.

FIG. 5 is an analytic perspective view of a knee pad assembly and knee pad cover according to example embodiments.

FIG. 6 is a perspective view of the knee pad base 302 from FIG. 5.

FIG. 7 is an analytic perspective view of a knee pad assembly and knee pad cover according to example embodiments

FIG. 8 is an analytic perspective view of a knee pad assembly according to example embodiments.

FIG. 9 is an analytic perspective view of a knee pad assembly according to example embodiments.

FIG. 10 is an analytic perspective view of a knee pad assembly according to example embodiments.

FIG. 11 is an analytic perspective view of a knee pad assembly according to example embodiments.

FIG. 12 is an analytic perspective view of a knee pad assembly according to example embodiments.

FIG. 13 is an analytic perspective view of a knee pad assembly according to example embodiments.

FIG. 14 is an analytic perspective view of a knee pad assembly according to example embodiments.

FIG. 15 is an analytic perspective view of a knee pad assembly according to example embodiments.

DETAILED DESCRIPTION

In the following descriptions, the present invention will be explained with reference to various example embodiments; nevertheless, these example embodiments are not intended to limit the present invention to any specific example, embodiment, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention. The invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

Referring to FIG. 1 and FIG. 2, a knee pad assembly 100 is shown. The assembly generally comprises a base 102 and a removable cover 104. The base 102 fastens to the user's knee using fastening straps 106, such as the ratcheting adjustable straps as shown in these figures with ratcheted fastener 109. An upper and a lower strap are shown but more or fewer straps are within the scope of the invention. The base 102 presents a forward facing cover receiving portion 108. The cover 104 is disposed over the forward facing portion 108 of base 102 as indicated in these figures and secured via attachment means, in this example via corner hooks 110 disposed at the corners of base 102. The assembled knee pad 100 is shown in FIG. 2.

The knee pad base can be configured in short or long versions as appropriate for the particular application and a user's desired level of coverage. The cover is correspondingly sized.

The cover may be formed from any suitable material, including rubber and plastic, and formed in any suitable shape. In addition, the cover may fully or partially comprise multirole materials such as leather, cloth, plastic, fiber glass, foam, rubber, carbon fiber, composites, metal or any other material that is designed for the end user's specific job requirements.

A wide variety of cover attachments means are within the scope of the invention. Such means include, but are not limited to hooks, snaps, clips, hook and loop components (e.g. VELCRO fasteners) on respective portions of the base and cover, and combinations of two or more different attachment means.

The user's ability to change covers on the knee pad bases allows for a single pair of knee pads to be adapted to a wide variety of surface types. The ability to change covers also provides the user with the option to replace individual worn covers, wash soiled covers, and/or use job specific covers as needed, avoiding the need to purchase a replacement or additional set of knee pads.

Referring to FIGS. 3 and 4, another example embodiment of a knee pad assembly 200 is shown. The base 202 is provided with one or more front facing suspension components 212, such as rubber or foam pads. In this example embodiment, base 202 is slideably engaged with pad 204 by straps 214 that are integrated into the corners of pad 204. Straps 214 secure the knee pad assembly 200 to a user by wrapping straps 214 securely around the back of the users knee. It should also be noted that straps 214 could also be integrated with base 202 and slide through corresponding openings (not shown) in pad 204 to also achieve the floating suspension effect. Cords may also be used instead of straps.

While secured, the back surface of pad 204 engages the suspension member 212 of base 202, and slides on guide rails 216, allowing pad 204 to float on suspension member 212 and remain aligned via guide rails 216, without being fixably connected to base 202. This allows pad 204 to move in toward the knee and out away from the knee, depending on the pressure exerted on the front surface of pad 204 while in use. This provides cushioned suspension for the knee while the improved knee pad assembly is in use. The spring force of the compression component 212 may be adapted to a desired range of cushioning or compression based upon a user's weight, and/or the conditions of use of the knee pad, and/or the length of time of intended use. Preferably a material with an ILD (Indention Load Deflection) of between 45 and 100 may be used. Urethane and other foams may also be used with densities of weights between 1 and 10 pounds per square foot of material. The outer cover 204 may comprise a semi-rigid or a hard plastic shell (or similar material) that will compress one or more of the suspension components 212 and distribute the force over the cover 204. The cover 204 cooperates with a plurality of integrated straps 214, guide rails 216 and guide plate 218 to facilitate slideable engagement, and uniform alignment, of the cover to the base.

This example embodiment also illustrates a tension/release mechanism or feature. When kneeling, compression placed on the cap 204 would compress suspension components 212 and release strap tension on straps 214 and when standing, compression would be released and strap tension would be allowed to return. The purpose is to release strap tension on the back of the worker's leg, nerves and blood vessels while the worker is kneeling, yet maintain security of the knee pad when the worker is standing or walking. The cap 204, straps 214, suspension components 212, guide rails 216 and guide plate 218 cooperate to achieve this feature, as well as providing a uniform alignment of the cap 204 with the base 202, and providing extended comfort to the user.

Referring to FIGS. 5 and 6, another embodiment of a knee pad assembly 300 is shown. The base 302 comprises a knee cup 304 and a suspension member 306 disposed on the outer front surface of the base. An outer cover or shell 308 is disposed over knee cup 304 and suspension member 306 by straps 310. This arrangement allows force applied to the cover to compress the collapsible or suspension member towards the base to provide cushioning. The edges of the cover 308 slide toward the user's knee along the outer perimeter surface of the base. When the pressure on the cover is released, the suspension member 306 expands to its original shape. In one variant, the suspension member 306 is partially collapsible in order to provide adequate support and air space while collapsible enough to provide desired cushioning. In addition open areas 312 in suspension member 306 allow additional cushioning and support for the knee. Similar to the embodiments described and depicted in FIGS. 3 and 4, the contact and cooperation between cover or shell 308 and suspension member 306 provides a floating type suspension for the knee while the knee pad 300 is strapped to a user by straps 310.

Referring to FIG. 7, depicted is yet another exemplary embodiment where knee pad assembly 400 is comprised of base 402, which is a partial shell that is disposed behind the user's leg, such as on the calf and behind the knee, and cap 404. For example, straps or a neoprene back of leg wrap 402 may be substituted for the base and straps described in the preceding examples. The cover 404 is then placed over the knee cap and restrained in place via tension members 418, such as cords, on either side of the base spanning between the base and the cover. This arrangement promotes good pressure management on the user's knee and leg. The cover 404 is shown with a honeycomb pattern 420 in a soft rubber material in order to enhance traction and provide cushioning for the user. A further feature illustrated in this example is the ratchet system 422 disposed on top of cover structure 404 and functionally connected to the tension members 418. Via the ratchet system 422, the wearer has the ability to tighten or loosen strap pressure (snugness) of the knee pad. A dial 424 or other user actuator is provided to allow the user to actuate the ratchet system.

Referring to FIGS. 8 through 15, depicted are various means to removeably attach a pad to a base. FIG. 8 provides a base 502 with one or more sleeves or pockets 504 to receive the tongues 508 of cover 506. The front receiving surface 510 of the base 502 and back surface 511 of cover 506, may further be provided with a respective portion of a hook and loop fastener 512 to further secure the cover to the base. The cover 506 shown in this example is a generally rectangular and slightly curved semi-rigid board comprising a polyethylene material. However, the board can vary in size, shape and material as appropriate for the particular usage.

Referring to FIG. 9, an exemplar knee pad assembly is shown with another cover fastening means. An elastic hem 522 is provided around the perimeter 524 of the cover receiving surface 526 of the base 520. The perimeter 528 of the cover 530 includes corresponding protruding tabs or projections 532 that are sized and shaped for being received in the elastic hem 522. Hook and loop 527 may also be used as shown in FIG. 8, and can further be used with all embodiment disclosed herein.

Referring to FIG. 10, a further embodiment of a knee pad assembly is shown. The base and cover is shown in FIG. 9. In addition, an overlay cover 534 is now provided. The overlay cover 534 is disposed over the cover 530 and then secured to the base with a plurality of reinforced strap loops 536. The straps 538 used to secure the base to the knee region of the user are placed through the reinforced loops 536 of the overlay cover 534 to secure the cover and overlay in place.

Referring to FIG. 11, another embodiment of a knee pad assembly is shown. The cover or overlay 540 includes a plurality of elastic bands or cords 542. The cords 542 can extend through the cover 540 for better securement. A tab 544 is provided at an approximate mid-point of each band 542. The cover 540 is secured to the base 546 by inserting the tabs 544 into respective slots or pockets 548 in the base 546. Channels 550 in the outer perimeter surface 552 of the base 546 may be provided to further retain the bands in place. Hook and loop fasteners 554 may further be provided on respective portions of the cover and base to further secure the cover to the base.

FIG. 12 illustrates a cord-lock means 562 for securing the cover 564 to the base 566. Raised corners 568 on the cover are inserted behind portions of the locking cord 570. The locking cord or cords 570 are then tightened by pulling on cords 563 and retainer 562 is then used to maintain the tension in the retaining cord(s).

FIGS. 13 through 15 illustrate other exemplar attachment embodiment means for a knee pad assembly. The cover or overlay 578 includes a plurality of elastic bands or cords 572 shown at the corners of the cover 578. The cords can extend through the cover in a crossing pattern or “X” shape 574 for better securement, as shown in FIG. 14. A tab 576 is provided at an approximate mid-point of each band 572. The cover 578 is secured to the base 580 by inserting the tabs 576 into respective slots or pockets 582 in the base at the corners thereof. The corner pockets may be raised to facilitate insertion and removal of the tabs. FIG. 15 further illustrates that cover 578 may be used to secure pads used in previous embodiments to a base such as base 580. Note that the underlayment of pad 584 of FIG. 15 includes a plurality of slots 586 for receiving the knee pad retaining straps 581.

The compressibility factor (including material property and physical dimensions and shape) of the collapsible or suspension members disclosed herein can be varied to accommodate different user weight ranges and to accommodate a user's desired cushioning factor. The cover can be secured using a variety of means as discussed in this disclosure. Alternatively, the cover may include straps that secure the assembly directly to the user's knees, such as elastic cord or adjustable straps that extend behind the knee of the user.

The collapsible or suspension members may comprise a wide variety of materials, including, springs, pen cell foam, closed cell foam, air bag, molded EVA, soft 3D fabric (spacer mesh), a resilient honeycomb structure, rubber, or any combination of these or other materials.

The cushioning factor can also be selected according to body weight or according to average time spent kneeling/hour. For example, body weight ranges of 80 to 150 lb, 150 to 225 lb, and over 225 lb; kneeling 10 min./hour, 30 min./hour and 50 min./hour. However more or fewer ranges may be specified.

Features of the various embodiments discussed herein can be mixed and matched in any manner of additional embodiments that are all within the scope of the invention regardless of whether or not explicitly discussed herein.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. Moreover, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention.

For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim. 

1. An improved knee pad assembly comprising: A base having a front surface and a back surface, the back surface of the base shaped to substantially conform to the contours of a human knee, a pad member having a front surface and a back surface, the pad back surface being shaped to substantially cover the base front surface, a suspension component, disposed between and engaged with the base front surface and the pad member back surface, wherein the pad member back surface is sized and shaped to substantially contact the suspension component, providing a floating suspension for the pad member, and, wherein the base has integrated therewith an attachment element, the attachment element configure to slideably pass through the pad member for removeably attaching the knee pad assembly to a user.
 2. The improved knee pad assembly of claim 1 wherein the attachment element is a strap or cord.
 3. The improved knee pad assembly of claim 1 wherein the suspension component has an ILD of between 45 and
 100. 4. The improved knee pad assembly of claim 1 wherein the suspension component is distributed primarily around a parameter of the base front surface.
 5. The improved knee pad assembly of claim 3 wherein the suspension component also has a cross member component.
 6. The improved knee pad assembly of claim 1 wherein the suspension component is a substantially rectangular section of foam material.
 7. The improved knee pad assembly of claim 1 wherein the suspension component comprises, a guide member having a front surface and a back surface, the guide member being configured to accept a guide element, the guide member front surface being configured to substantially mate with the front surface of the pad member, the guide member front surface having disposed thereon a suspension element, and, wherein the base contains the guide element that is configured to slideably engage the guide member and engage the pad member.
 8. An improved knee pad assembly comprising: a rear base having a front surface and a back surface, the front surface adapted to fit the contours of the back of a human knee joint and leg, the rear based being sized to extend above and below the knee joint, a pad member having a front surface and a back surface, the pad member back surface being adapted to fit the contours of a human knee, and, an attachment member configured to engage both the pad member and the rear base to secure the knee pad assembly to a user.
 9. The improved knee pad assembly of claim 8 wherein the front surface of the pad member is covered substantially with a resilient material in a honeycomb configuration.
 10. The improved knee pad assembly of claim 8 wherein the attachment member is attached to the pad member and releaseably engages the rear base.
 11. The improved knee pad of claim 10 wherein the attachment member is an elastic cord.
 12. The improved knee pad assembly of claim 11 wherein the pad member includes a releaseable ratchet element that cooperates with the attachment member to allow the attachment member to be tightened and loosened with one hand.
 13. An improved knee pad assembly comprising: a base having a front surface and a back surface, the back surface of the base shaped to substantially conform to the contours of a human knee, a pad member having a front surface and a back surface, the pad back surface being shaped to substantially cover the base front surface, an attachment means disposed on the base and the pad member for removeably attaching the pad member to the base, a base attachment element configured to pass around the back of a human knee joint, both above and below the joint, to secure the base to a user, and, a releaseable ratchet element disposed on the front surface of the base, the releaseable ratchet element configured to allow the user to tighten or loosen the base attachment element with one hand.
 14. The improved knee pad assembly of claim 13 wherein the base attachment elements are straps.
 15. The improved knee pad assembly of claim 13 wherein the pad members are disposable.
 16. The improved knee pad assembly of claim 13 wherein the front surface of the pad members substantially incorporates one or more of the materials from the group: leather, cloth, plastic, fiber glass, foam, rubber, carbon fiber, composites, metal.
 17. The improved knee pad assembly of claim 13 where the pad member is configured to be interchangeable with a replacement pad member with a front surface which substantially incorporates a material different from the pad member front surface being replace, the replacement pad member front surface being substantially comprised of one or more of the materials from the group: leather, cloth, plastic, fiber glass, foam, rubber, carbon fiber, composites, metal. 